Dodge Ram Truck 2500 Series 2002 Workshop Service Repair Manual

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🏷️ Basic Information Identification Make: Dodge Model: Ram Truck 2500 Series Year: 2002 Product Type: Workshop Service Repair Manual Codes Platform Code: DR Chassis Code: 2500 Series 👋 Introduction Market...

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Description

🏷️ Basic Information

Identification

Make:

Dodge

Model:

Ram Truck 2500 Series

Year:

Product Type:

Workshop Service Repair Manual

Codes

Platform Code:

Chassis Code:

2500 Series

👋 Introduction

Market Position

Category:

Heavy-Duty Pickup Truck

Target Audience:

Owners, DIY mechanics, professional technicians

Competitive Analysis

Competitors:

Ford F-Series Super Duty, Chevrolet Silverado HD, GMC Sierra HD

Key Features

Vehicle Strengths:

Robust construction, towing and hauling capability, powerful engine options

Manual Value Proposition:

Enables comprehensive maintenance and repair, reducing reliance on costly dealership services and extending vehicle lifespan.

📋 Manual Details

Coverage Areas

Covered Models:

All Ram 2500 Series Models

Covered Engines:

All Engine Variants (specifics to be detailed in engine_specs)

Page Count

Estimated Pages:

1000+

Manual Type

Type:

Workshop Service Repair Manual

Language

Language:

English

Format

Format:

PDF Download

📖 Manual Coverage

Systems Covered

Powertrain:

Engine mechanical, cooling, lubrication, fuel, exhaust, ignition, engine control systems (ECU/PCM)

Transmission:

Automatic and Manual Transmission diagnosis, repair, overhaul, fluid specifications, shift control

Drivetrain:

Transfer case, drive shafts, axles, differentials, CV joints

Chassis:

Suspension (front and rear), steering system, braking system (ABS, disc/drum components), wheel bearings, hubs

Electrical:

Battery, charging system, starting system, lighting, instrument cluster, power windows, locks, mirrors, audio system, trailer wiring, fuses, relays, wiring diagrams

Body And Trim:

Exterior panels, interior trim, doors, windows, seats, HVAC system (heating, ventilation, air conditioning), body control module (BCM)

Procedures Included

Maintenance:

Scheduled maintenance (oil changes, filter replacements, fluid checks), component lubrication, inspections

Troubleshooting:

Diagnostic procedures, symptom-based troubleshooting, fault code interpretation (OBD-II), component testing

Repair:

Component removal, installation, overhaul, adjustment procedures for all major systems

Diagnostics:

Detailed diagnostic flowcharts and procedures for engine, transmission, ABS, SRS, and other electronic systems

Specifications:

Torque specifications, clearances, fluid capacities, electrical resistance values, pressure readings

Technical Depth

Depth:

Comprehensive: Covers basic maintenance to full engine and transmission rebuilds, advanced electrical diagnostics, and structural repairs.

📊 Manual Specifications

File Format

File Type:

Searchability:

Fully searchable text content

Print Quality

Resolution:

High-resolution images, diagrams, and schematics

Scalability:

Scalable diagrams for clear viewing of details

Binding Type

Binding:

N/A (Digital Download)

Paper Type

Paper:

N/A (Digital Download)

⚙️ Engine Specifications

Primary Engine

Base Engine:

8.0L V10 Magnum

Optional Engine 1:

5.9L Cummins Turbo Diesel (ISB)

Optional Engine 2:

5.7L V8 HEMI (introduced mid-year/late 2002 for some models, confirm specifics)

Optional Engine 3:

5.9L V8 Magnum

Performance

8.0L V10 Horsepower:

305 hp @ 4000 rpm

8.0L V10 Torque:

450 lb-ft @ 3200 rpm

5.9L Cummins Horsepower:

235 hp @ 2300 rpm (est. for 2002)

5.9L Cummins Torque:

460 lb-ft @ 1400 rpm (est. for 2002)

5.9L V8 Magnum Horsepower:

245 hp @ 4000 rpm

5.9L V8 Magnum Torque:

335 lb-ft @ 3200 rpm

Fuel System

8.0L V10:

Multi-point Fuel Injection (MPI)

5.9L Cummins:

High-pressure Common Rail (Cummins ISB - later models), or VE rotary injection pump (earlier models - confirm for '02)

5.9L V8 Magnum:

Multi-point Fuel Injection (MPI)

Ignition System

V8/V10:

Distributorless Ignition System (DIS) with coil-on-plug or coil packs

Cummins:

Compression Ignition (Diesel)

🔧 Transmission

Standard

Transmission Type:

4-speed Automatic (47RE/48RE for V8/V10, likely NV4500 5-speed manual for some diesel models)

Optional

Transmission Type:

5-speed Manual (NV4500 for diesel models, possibly others)

Features

Automatic Transmission Control:

Electronic controls (TCM) for shift points and line pressure

Fluid Specifications

Automatic Fluid:

Chrysler ATF+4 (Mopar)

Manual Fluid:

Refer to manual for specific NV4500 fluid type (typically GL-4 or GL-5 gear oil)

📐 Dimensions

Exterior

Wheelbase Regular Cab:

134.1 inches

Wheelbase Extended Cab:

147.3 inches

Wheelbase Crew Cab:

160.5 inches

Cargo

Bed Length Standard:

6.3 feet (75.9 inches)

Bed Length Long:

8.0 feet (96 inches)

Weights

Gvwr:

Typically 8,500 - 9,500 lbs (varies by configuration)

Gcwr:

Up to 23,000 lbs (depending on configuration and engine)

Curb Weight:

Varies significantly by configuration (est. 5,800 - 7,000 lbs)

🛡️ Safety Features

Ratings

NHTSA Frontal Crash Driver:

Not directly rated in this era for HD trucks, but design focus on occupant protection.

NHTSA Frontal Crash Passenger:

Not directly rated in this era for HD trucks, but design focus on occupant protection.

IIHS Offset Frontal:

Not extensively tested by IIHS for this specific model year/configuration.

Active Features

Standard Anti-lock Braking System

Traction Control:

Optional on some models

Passive Features

Airbags:

Driver and Passenger front airbags

Seat Belts:

Three-point front and rear seat belts

Child Seat Anchors:

LATCH system may be present on specific seating positions, check manual for details.

💡 Technology Features

Infotainment

Audio System:

Factory AM/FM CD player, optional cassette, Sirius Satellite Radio (availability varies)

Display:

Basic digital display for radio and clock, instrument cluster with analog gauges

Driver Assistance

Cruise Control:

Standard

Parking Assist:

Optional rear park assist sensors

Connectivity

Trailer Connection:

Factory-installed trailer wiring harness with 4-pin and 7-pin connectors (depending on towing package)

🔧 Maintenance

Service Intervals

Oil Change Interval Gas:

3,000-7,500 miles or 6 months (refer to manual for exact usage-based recommendations)

Oil Change Interval Diesel:

3,000-7,500 miles or 6 months (diesel engines often require more frequent changes based on duty cycle)

Transmission Fluid Change:

Every 30,000-60,000 miles, depending on towing and load conditions (refer to manual)

Coolant Change:

Every 30,000-100,000 miles, depending on coolant type (Mopar HOAT or OAT - check manual)

Fluid Specifications

Engine Oil Gas V8 V10:

SAE 5W-30 or 5W-40 (check manual for specific engine and temperature range)

Engine Oil Diesel Cummins:

API CJ-4 or CK-4 rated 15W-40 (check manual for exact specification)

Coolant Type:

Mopar Antifreeze/Coolant (MS-9769 - HOAT Orange) for gas engines, Mopar Antifreeze/Coolant (MS-2000 - OAT) or equivalent for Cummins diesel (verify in manual)

Brake Fluid:

DOT 3

Power Steering Fluid:

Mopar Power Steering Fluid or ATF+4

Known Issues

Common Complaints Gas:

Valve seat recession in V10, occasional misfires, intake manifold leaks

Common Complaints Diesel:

VP44 injection pump failure (early models, less common on later ISB), lift pump issues, injector problems

Common Complaints Chassis:

Ball joint wear, universal joint wear, exhaust manifold cracking (especially on V10), ABS sensor failures

Common Complaints Transmission:

Overdrive planetary gear failure in automatics, clutch wear in manuals

Body Issues:

Rattling interior trim, potential rust on rocker panels and cab corners (depending on climate)

📚 Vehicle History

Brand Heritage

Dodge Truck Legacy:

Dodge has a long history of producing robust and capable trucks, with the Ram line evolving from the earlier Dodge D-Series.

Model Evolution

Third Generation Ram:

The 2002 model is part of the third generation (2002-2008) of the Dodge Ram, marked by a significant redesign with a more aggressive styling and improved interior.

Production

Manufacturing Location:

Saltillo, Mexico; Warren, Michigan

Model Year Introduction:

The third generation Ram debuted for the 2002 model year, with some minor powertrain updates continuing through the generation.

🏆 Awards & Recognition

Recognitions

Segment Performance:

Ram trucks in this era were often recognized for their towing and hauling capabilities and robust powertrains, particularly the Cummins diesel.

Ratings

Consumer Satisfaction:

Varies by specific engine and configuration, but generally competitive within the heavy-duty segment for its capabilities.

Certifications

Emissions Standards:

Meets EPA and CARB emissions standards for the 2002 model year.